Armature



Oct. 4, 1932. Q v, 3, APPLE ET AL 1,881,341

ARMATURE Filed June 15, 1929 3 Sheets-Sheet l NVENDE Oct. 4, 1932. v. e. APi=LE ETAL ARMATURE Filed June 13, 1929 3 Sheets-Sheet 2 //v VENTURE jvz Oct. 4, 1932. v APPLE ET AL 1,881,341

ARMATURE Filed June 13, 1929 5 Sheets-Sheet 3 N UR Ti .14. Fi 1W 9 5 f vmcnnr e.

Patented Oct. 4, 1932 UNITED STATES PATENT; ori ice APPLEAND FREDERICK w. COT'IIFBEAH, F DAYTON, 0310, ASSIGNOBS '10 VINCENT. G. APPLE LABORATORIES, 0F DAYTOIL'OBIO .ABHA'I'UBE Application filed June 18.1929. Serial No. 370,702.

This invention relates to armatures of the class comprlsing a slotted core, a winding of insulation covered wire and a commutator.

An object of the invention is to generally improve the structure of 'anarmature of this type. A more specific object is to provide a structure'wherein the core, the turns of wire com-- posing the winding, and the bars composing the commutator are all imbedded in the same substantially continuous mass of insulating material whereby they are permanently hel in spaced relation and protected against the harmful effect which results when oil, moisture or other foreign matter ispermitted to enter into the spaces between the conductive portions of the structure as in common praced to a structure of this type.

Further objects will become a parent as the invention is described in detail and reference is made to the drawings, wherein Fig. 1 shows the core of the armature selected to illustrate the invention.

' Fig. 2 shows the core Fig. 1 with the slots lined with sheet insulation preparatory to placing the winding thereon, and with collars at the ends of the core to keep the winding spaced apart from the shaft as it is being placed. 1

Fig. 3 shows the winding in place with extending leads formed of the ends of the wire composing the coils.

Fig. 4.- shows a blank punched from sheet metal whichis afterward bent to compose a commutator segment. 7

Fig. 5 shows the commutator segment bent from blank Fig. 4.

Fig. 6 shows a wound structure Fig. 3 with a sggment Fig. 5 electrically joined to each lea Fig. 7 is a vertical axial section through a tool used to arrange the segments, of the structure Fig. 6 in proper spaced relation.

Fig. 8 shows the tool Fig. 7 in perspective.

Fig. 9 is a ring for holding the segments Fig. 5 to the tool Figs. 6 and 10 shows the tools Figs. 7, 8 and 9 assembled on the armature to locate the commutator segments. 11 is a vertical axial section through a mold with the armature in process of being properly located and held therein.

Fig. 12 shows the armature in place ready to mold.

Fi 13 is a transverse section taken at 13- 13 0 Fig. 12. Fig. 14-..shows the armature in the mold after the insulation mass has been moldedabout it. Fig. 15 shows a com leted armature after removal from the mol Similar numerals refer to similar parts throu bout the several views. In t e drawings, a shaft 16 having a longitudinally extending keyway 17 carries a core 18 composed of a plurality of laminae 19. Laminaa 19 have a series of winding slots 20 separated by teeth 21, and integral keys 22 extend inwardly into keyway 17 whereby slots 20 are held in definite relation to keywag 17.

lots 20 are lined as in Fig. 2 by placing a continuous strip of insulation 23 around the core and looping it downward into each slot as at 24. Collars 26 and 27 are placed over the shaft 10, but remain-there only while the winding is being put on the core.

Fig. 3 shows the core with the coils 28 wound in the slots. But before winding the wire into coils it is preferably treated by the processillustrated and described in co-pending application Serial No. 356,586, filed April 19th; 1929, to make sure that the pressure incident to the subsequent molding operation will not break down the insulation between adjacentturns. Leads 29 are formed by joining the end of one coil to the beginning of the next as in common practce. After the coils are wound into the slots the continuous strip of insulation 23, Fig. 2 is cut apart between the slots and the ends tucked in over the wire in each slot as at 30, leaving a longitudinally extending open space 31 (see Figs. 3 and 6) above each coil at the periphery of the core, the purpose of which will hereinafter appear.

"a Fig. may be lotherwise produced. The segment comprises the curved brush track portion 34, the anchor adapted to extend into I the insulation to hold the segment in )lace,

. 42 and 43 extending around it.

and the eculiarly curved riser 36 wit 1 the trou h 3% across the end, adapted to lay close y upon the coils and extend toward the core whereby the wire leads connecting the coils to the segments are shortened.

Fig. 6 shows the structure after the segment 32 has been connected to each lead29 by laying the lead into the trough 37 and welding, soldering, or otherwise joining it thereto.

After all of the segments are joined to the leads a methodof composing a commutator from the segments is provided. This consists briefly in temporarily holding the segments in the exact spaced relation which they occupy in the finished commutator and molding insulation, within, between and about them while they are so held, hardening the insulation, then removing the temporary holding means, and since it is one of the objects of the invention to have the same substantially continuous mass of insulation bind the segments together and extend round about the windings to enclose them, the tools are made to accomplish this object in the one operation, though of course a core of insulaton may be molded about segments 32 to compose a commutator and the commutator connected to the leads and a cover of insulation molded over the winding in a separate operation, if so desired.

' Fig. 7 is a vertical axial section through the tool 38 into which the se ments 32 are temporarily assembled in or. er that they may be more easily entered into the mold. The tool, also shown in perspective in Fig. 8, consists of a cylindrical body 39, bored at 40 and counterbored at 41, with annular grooves The counterbored portion 41 is divided by a series of longitudinal cuts 44 into prongs 45, and each prong is further milled at its outer diameter from the free end to the groove 43 to pro vide an integral key 46extending outwardly therefrom A plug 47, bored at 48 is fitted into opening 40 and secured by pin 49. An- Zgher pin 50 extends inwardly into opening When an armature has been wound and has its commutator segments 32 connected to the leads 29 as shown in Fig. 6, the collar 26 is removed and the tool 38 is placed over the shaft 16 with pin 50 in keyway 17 of the shaft. The segments 32 are then laid around the tool with the anchors 35 extending inwardly into the cuts 44 (see Fig. 10) and with keys 46 of the tool extending outwardly assna41 between segments 32. By this means the segments are held spaced apart and in correct relation to the winding slots 20 of core 18. Ring 51, Fig. 9 is now forced over the outside of the segments 32, the prongs 45 of the tool springing slightly inward to )er-mit the ring to go over. Several turns 0 insulation treated twine 52 may be wound about the armature in the troughs 37 to locate the risers 36 more permanently. The structure now appears as in Fig. 10 and after removal of collar 27 is ready to. be placed in the mold.

By reference to Fig. 10 it will be apparent that the risers 36 overlie the winding closely, and that they extend toward the core to such a degree that very short leads 29 only are required. 'It will also appear that after 001- lars 26 and 27 are removed from between shaft 16 and the winding, the openings 53 and 54 extending radially between the core and'the coils at each end of the core and the spaces 55 between the outer end of the winding and the commutator segments will permit plastic insulation to flow-radially from the spaces within the winding vacated by 1 removal of the collars 26 and 27 to the spaces around the outside of the winding and vice versa, when the commutator core and the covering for the winding is being molded thereabout.

The mold 56, for placing the mass of insulation composing a core for the commutator and a covering for the winding, is shown in three stages of its operation in Figs. 11,,

12 and 14 and comprises a body 57, bored at its lower end at 58 to a diametersli htly larger than the commutator, at its middle portion 59'to fit the core 18, and at its upper end 60 to receive the plunger 61. The ortion 62 is bored slightly larger than the wmding which it surrounds but not as large as the core, and the plunger 61 is hollowed out at its lower end at 63 to correspondingl surround the winding at the upper end. X chuck jaw spacing ring 64, havmg a series of radial grooves 65 (see Fig. 13) to slidably receive chuck jaws 66, is secured to the lower end of body 57 by screws 67. Chuck jaws 66 each have a segment spacing tang 68 extending radially inward from them inner ends. The lower end of body 57 is turned to rotatably support a chuck ring 69 which has a scroll 70 cut in its lower surface and bevel-gear teeth 71 in its upper surface. The

upper edges of the chuck jaws 66 have teeth 72 meshing into the scroll 70, and bod '57 is bored at 73 to receive pinion wrenc 74 which engages bevel-gear teeth 71 to rotate ring 69 to give radial movement to the chuck aws.

A base plate 75 is bored to the diameter of the finished commutator at 76, and an annular rib. 77 extends into chuck jaw spacing ring 64 to maintain concentric relation bet-ween the plate and ring.

In operation the plunger 61 and the base plate 75am removed, pinion wrench 74 1s turned until chuck jaws 66 move radially der 7 8 of the mold body 57.

The jaws 66 are now moved radially inward by turning pinion wrench 'i i'until the spacing tangs 68 enter the spaces between the segments 32, the prongs 45 of tool 38, then springing inward sufliciently to permit each segment to be securely clamped between adjacent tangs, after which the tool 38 is Withdrawn from the commutator and from the mold and the base plate 75 is put in place.

The armature and mold, together with the plunger 61, are now heated and maintained in a heated state long enough to harden the insulation treated coils, then a determined quantity of moldableinsulation compound is placed the opening 60, the plunger 61- is inserted, and as soon as the compound absorbs suflicient heat from the body 57 and the plunger 61 to become mobile, the plunger is forced downward tov the position shown in Fig. 14, pressing the insulation first about the upper ends of the coils within the space 63, and radially through openings 54 (see Fig. 10) between the coils and the core, then downwardly through spaces 31 (see Figs. 6 and 10) into the space 62, then radially inward through openings 53 (see Fig. 10) into the space vacated by collar 26, (see Figs. 3 and 6), alsoradially inward through spaces (see Fig. 10) into the interior of the commutator aboutthe anchors 35 to form the commutator core which binds the se ments together, and a complete covering or the winding at both ends of the core and over that portion within-the core slot, all inte al.

The mold is held completely close as shown in Fig. 14 until the stored heat of the mold hardens the mass of plastic insulation whereupon the armature is pressed out complete-except for the very slight trueing up of the outside diameter of the commutator. The complete armature is shown in Fig. 15.

The advantages of the invention become more obvious b referring to Fig. 10 and considering the e ect of eliminating the curved risers 36 and instead having the fine wire leads 29 extend from the core18 across the open spaces 55 to be joined to the se ments 32 as in common practice, and then orcing insulation of indifierent fluidity radially I through the spaces 55 past the fine wire leads which are stretchedacross the path of themoving insulation. It is readily apparent that such a procedure would be taken at considerable risk of tearing the leads from their connection to the segments while molding was being efiected- Besides facilitating the placing of'the in,- 4. An armature comprising a slotted mag- 13:

sulation, an improved product is made where v core, forming relatively short leads of the coil ends, providing commutator segments having long curved risers anda groove crosswise of the risers at their outer ends, electrically joining asegment to each lead, arranging the segments in cylindrical j formation with the risers closely overlying the winding head, winding cord circumferentially about the winding head into the riser grooves to I bind the risers .to the winding head, placing the structure in a mold, and molding insulation within,'between and about the segments about the winding head and risers.

2. The method of making a wire wound armature, which consists of winding coils into the slots of a core, leaving slight space in thetops of the slots unfilled, bringing out leads from the front head, attachinga commutator segment to each lead, arranging the segments in cylindrical formation, placing the struc: ture in a mold, placing a quantity of moldable insulating compound about the back head, and, with a plunger, forcing it about the back head, then through the unfilled slot space about the front head, thence radially inward to compose a commutator and to form a cover 7 within the commutator structure to tie the segments together. i

3. An armature comprising a slotted magnetic core, coils each comprising a plurality ofturns of insulated wire in the slots of said core and extending axially beyond the ends of the core forming coil heads, a single hub of hardened cementitious insulation extending from one end of the core axially considerably farther than the coil head, said-coil head being imbedded in, penetrated by and completely surrounded by the'inner end of said hub, a cylindrical rowof spaced apart commutator segments overlying that part of the hub which extends axially beyond the coil head, integral anchors on said segments ill) securing the outer ends of said segments to said hub by extending from the outer ends of the segments inwardly into the hub near ,its outer end, and integral risers on said segto said hub by extending from the inner ends of the segments lengthwise'within said hub toward and substantially to said core, said coils having short wire leads connected to the ends of said risers adjacent said core.

: tures.

netic core, coils each comprising a plurality of turns of insulated wire in the slots of said core and extending axiall' be 0nd the ends of the core forming coil eadh, an integral hub of hardened cementitious insulation extendin axially from one end of the core, said hub being of two diameters with the larger diameter next to the core and the coil headw being imbedded in, penetrated by, and com-- pletely surrounded by thesaid larger diametered portion, a cylindrical row of spaced apart commutator segments surrounding the smaller diametered portion of the hub,-

integral anchors on said segments securing the o' ter ends of :said segments to said hub by ex ending from the outer ends ofthe segments radially inward then axially toward the core near the outer end of thesmaller diametered portion, and integral risers on said segments securing the inner ends of said segments to said hub by extendin' from the inner ends of the segments radialy outward then axially toward and substantially to said core over the outside of the coil head I and within the larger diametered portion of said hub, said coils having short leads connected to the ends of said risers adjacent said core.

In testimony whereof we afiix our signa- VINCENT G. APPLE. FREDERICK W. CQTTERMAN. 

